Energy Efficiency Bulletin

Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre

Bulletin No. 19

Initiatives taken towards Optimising Air Conditioning Load

October 2007

Company details Bharat Heavy Electricals Limited (BHEL) is a Gas and Steam turbine manufacturer in India. It is one of the nine largest Public Sector Undertakings and a key player in power sector through erection, commissioning and servicing of power plants all over the world. Bharat Heavy Electricals Limited (BHEL), established in the mid fifties, has today emerged as the largest engineering and manufacturing enterprise of its kind in India and ranks amongst the top ten power generation equipment manufacturers in the world. The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the major manufacturing plants of BHEL. The core business of HEEP includes design and manufacture of large steam and gas turbines, turbo generators, hydro turbines and generators, large AC/DC motors and so on. Project details A latest air conditioning system was installed for turbine blade shop at BHEL, Haridwar. The capacity of chiller used for both turbine blade shop & annex building air conditioning is 300 TR. The effective roof height is 4m in turbine blade shop and 2.7m in annex building. The annex building was directly exposed to sunlight. Salient features of the project
l l l l

was installed to automatically control the exact quantity of fresh air required. The air flow was controlled based on temperature of inlet & return air in the system. The regulation of air flow based on return air temperature has resulted in saving energy Building Management System is designed to allow controlled intake of fresh air from out side during winter season thus minimizing the chiller operation Automatic Temperature Control in air conditioned spaces was achieved by means of temperature, humidity sensors and 3-way chilled water valve Heat reflecting high performance glass was installed on exposed windows to cut down on the air conditioning load due to direct solar radiation. A high performance glass is one having a Low Shading Coefficient (0.1 to 0.4 W / m2 deg K), a Low U Value ( 1.7 to 3.0 W/m2 deg K) & a High Visual Light Transmittance ( 40 %- 60 %)

Solar Radiation

2 Thick EPS / EQ. Insulation Slab

Over deck insulation The exposed roof was identified as a major contributor to heat impingement, resulting in higher air conditioning load. It was decided that usage of over deck / under deck insulation would reduce the heat impingement.

Energy efficient imported screw type water chillier of 150 TR x 2nos (water cooled) having totally automatic control features was installed

Environment friendly R-134a, Tetrafluroethane having no presence of chlorine and having Zero ODP (Ozone Depleting Potential) was used in the Air Conditioning System

An integrated Building Management System (BMS)

To reduce heat ingress into the building, an insulation of 50 mm thick Polyurethane foam was sprayed directly on the roof. This resulted in 10 % savings on AC load power consumption. Issues faced during implementation No major issue was faced during the implementation of the project. Comments from the plant team The project was implemented by Bharat Heavy Electrical (BHEL) Equipment plant, Ranipur, Haridwar (U.A.) in the year 2003. Air conditioned space is on the rise in India. Effective insulation of the air conditioned space is a must to reduce heat ingress, thus increasing energy efficiency of air conditioning. Financing of the project The plant invested about Rs 0.9 million (USD 0.022 million) for implementation of the project. The investment was taken up fully with internal funds. Results of the project Implementation of this project resulted in saving of 10% of the power consumption.The annual savings achieved was Rs 0.69 million (USD 0.017 million). The investment made was Rs 0.9 million (USD 0.022 million) with a simple payback period of 16 months. Replication potential Similar initiatives are possible in all air conditioned buildings having large roof area exposed to sunlight. Benefits of the project
l Reduction in air conditioning load l Energy Efficient operation of air conditioning

Cost benefit analysis

l Investment Rs 0.69 million (USD 0.017

million)
l Annual savings Rs 0.9 million (USD

0.022 million)
l Payback 16 months

About CII & CII-Godrej GBC CII is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it is India's premier business association, with a direct membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 national and regional sectoral associations. Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activities in India. About 3 Country Energy Efficiency The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information is available at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

system using IBMS

For further details contact

Mr S K Joshi Sr. DGM (ESX & SP), Energy Manager Bharat Heavy Electricals Limited (BHEL) Administrative Building 4 Heavy Electrical Equipment Plant BHEL, Ranipur, Haridwar - 249403 (U.A.) Ph: 1334-285266, 285499 Fax: 1334-226460 Email: skjoshi@bhelhwr.co.in

Mr K S Venkatagiri / Mr K Sivaram
Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032 Tel: 040-23112971 73, Fax: 040-23112837 Email : k.s.venkatagiri@ciionline.org / k.sivaram@ciionline.org www.greenbusinesscentre.com